Padmount Switchgear
Service Information
VFI Tester
Operating Instructions
Figure 1.
VFI Tester.
S285-10-7
030052KM
Contents
Safety Information ..................................................... 2
Description of Tester ................................................. 5
Hazard Statement Definitions ................................ 2
Operating Procedures .............................................. 6
Safety Instructions .................................................. 2
Control Tests .......................................................... 8
Product Information .................................................. 3
SCADA Accessory Tests ........................................12
Introduction ............................................................ 3
External Flux-Shift Tripper Tests ............................17
Acceptance and Initial Inspection .......................... 3
Battery Test ............................................................18
Handling and Storage ............................................ 3
Service Information ...................................................19
Quality Standards ................................................... 3
Appendices ................................................................20
Description ............................................................. 3
LCD Message Screens ..........................................20
Specifications ............................................................ 4
Control Board Reference Illustrations ....................21
New • July 2004
Printed in USA
1
VFI Tester Operating Instructions
!
SAFETY
FOR LIFE
!
SAFETY FOR LIFE
SAFETY
FOR LIFE
Cooper Power Systems products meet or exceed all applicable industry standards relating to product safety. We actively
promote safe practices in the use and maintenance of our products through our service literature, instructional training
programs, and the continuous efforts of all Cooper Power Systems employees involved in product design, manufacture,
marketing, and service.
We strongly urge that you always follow all locally approved safety procedures and safety instructions when working
around high voltage lines and equipment and support our “Safety For Life” mission.
SAFETY INFORMATION
The instructions in this manual are not intended as a substitute for proper training or adequate experience in the
safe operation of the equipment described. Only competent technicians who are familiar with this equipment
should install, operate, and service it.
A competent technician has these qualifications:
• Is thoroughly familiar with these instructions.
• Is trained in industry-accepted high- and low-voltage
safe operating practices and procedures.
• Is trained and authorized to energize, de-energize,
clear, and ground power distribution equipment.
• Is trained in the care and use of protective equipment
such as flash clothing, safety glasses, face shield,
hard hat, rubber gloves, hotstick, etc.
Following is important safety information. For safe installation and operation of this equipment, be sure to read
and understand all cautions and warnings.
Safety Instructions
Following are general caution and warning statements
that apply to this equipment. Additional statements, related to specific tasks and procedures, are located throughout the manual.
DANGER: Hazardous voltage. Contact with
hazardous voltage will cause death or severe
personal injury. Follow all locally approved safety procedures when working around high and low voltage
lines and equipment.
G103.3
!
WARNING: Before installing, operating, maintaining, or testing this equipment, carefully read
and understand the contents of this manual. Improper
operation, handling, or maintenance can result in
death, severe personal injury, and equipment damage.
!
G101.0
Hazard Statement Definitions
This manual may contain four types of hazard
statements:
DANGER: Indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
!
WARNING: Indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
!
CAUTION: Indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
!
CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in equipment damage only.
2
WARNING: This equipment is not intended to
protect human life. Follow all locally approved
procedures and safety practices when installing or
operating this equipment. Failure to comply can result
in death, severe personal injury, and equipment damage.
G102.1
!
WARNING: Power distribution equipment must
be properly selected for the intended application.
It must be installed and serviced by competent personnel who have been trained and understand proper
safety procedures. These instructions are written for
such personnel and are not a substitute for adequate
training and experience in safety procedures. Failure to
properly select, install, or maintain power distribution
equipment can result in death, severe personal injury,
and equipment damage.
G122.2
!
!
S285-10-7
SAFETY
FOR LIFE
PRODUCT INFORMATION
Introduction
Quality Standards
Service Information S285-10-7 provides operating
instructions for the VFI Tester device use in conjunction
with Cooper Power Systems Padmounted VFI
switchgear. Before operating this device, carefully read
and understand the contents of this manual.
ISO 9001:2000-Certified Quality Management System
For additional information, refer to the following applicable
service information bulletins:
• S285-10-1 Kyle ® Type VFI, Oil-Insulated, Vacuum
Fault Interrupter; Installation, Operation, and
Maintenance Instructions
• S285-10-2 Kyle ® Type VFI, SF6-Insulated, Vacuum
Fault Interrupter; Installation, Operation and
Maintenance Instructions.
• S285-15-1 Kyle ® Type Shrubline VFI, Vacuum Fault
Interrupter; Installation, Operation and Maintenance
Instructions.
• S285-75-1 Kyle ® Tri-Phase, TPG, and TPG with
SCADA Electronic Control Installation and Operation
Instructions.
Read This Manual First
Read and understand the contents of this manual and follow all locally approved procedures and safety practices
before operating this equipment.
Additional Information
These instructions cannot cover all details or variations in
the equipment, procedures, or process described, nor
provide directions for meeting every possible contingency during installation, operation, or maintenance.
When additional information is desired to satisfy a problem not covered sufficiently for the user's purpose,
please contact your Cooper Power Systems
Representative.
Acceptance and Initial
Inspection
This test set is in good condition at the factory and when
accepted by the carrier for shipment.
Upon receipt, inspect the test set thoroughly for damage
and loss of parts incurred during shipment. If damage or
missing parts are discovered, file a claim immediately
with the carrier.
Handling and Storage
Be careful during handling and storage of the Type VFI
Tester to minimize the possibility of damage. If the tester is
to be stored for any length of time prior to use, provide a
clean, dry storage area.
Description
The VFI tester is a current injection device designed to
simulate Fault Current for verification of minimum trip values and time current characteristics of Tri-phase and
TPG electronic control boards utilized in Kyle type VFI
padmounted switchgear.
Three internal flux-shift trippers enable confirmation of
the presence of sufficient levels of energy upon the
control board for operation of padmounted VFI flux-shift
trippers. The on-board flux-shift trippers also enable selfchecking of the VFI tester prior to general control testing.
Further flux-shift tripper capability enables verification of
operation of the flux-shift trippers within the VFI unit
under test, external to the VFI tester.
The tester has the capability to perform the following operational tests:
• Minimum-Trip Tests
• Time Current Curve Characteristic Tests
• Control Operation Test
• Instantaneous Trip Test
• Time-Current Curve Characteristics Modifier
• Limited Testing of SCADA accessory board functions
including verification of the minimum trip multiplier
function and inrush restraint feature.
• Battery Test
• Flux-Shift Tripper Tests
Test settings are adjusted via a series of rotary, toggle,
and push button switches on the front panel of the tester.
Banana jacks on the front panel facilitate connection of a
Fluke or equivalent multimeter for verification of fault current injection values. Simulated phase and ground fault
currents may be set in the range of 4-900 A by using the
millampere reading of the digital multimeter as directly
equivalent to reading the primary fault current in
amperes.
A two-line, 16 character LCD display provides tester status, TCC trip times, and battery test information.
The VFI Tester is fan cooled and features thermal protection circuitry which disables the tester if the internal
temperature exceeds 65°C. Additional overload protection is provided by an automatic time-out circuit which
limits testing to 5 minutes during unsupervised tests.
The VFI tester requires 120 Vac, single phase power for
operation. Inboard power is protected by a 8 A resettable
circuit breaker and is controlled by a large, illuminated
rocker type switch on the front panel. A three conductor
power cable is furnished with the tester.
3
VFI Tester Operating Instructions
SPECIFICATIONS
Input
Weight
AC Input: 120 Vac ±10% 60 Hz, single phase, circuit
breaker protected at 8 A.
15.87 kg (35 lbs) - cables excluded
Output
Temperature Range
4-900 mA actual, simulating 4-900 A fault current levels.
Continuously adjustable, through multiple ranges with
coarse and fine control.
Operating Range: 0° to 50°C
Instrumentation
LCD Display
Storage Range: -20°C to 65°C
CAUTION: Equipment misoperation. This
device must be operated in dry environments
only. So not operate it in rain, snow, or sleet. Failure to
comply can result in equipment misoperation and possible personal injury.
G141.0
!
16 character, 2-line LCD display.
Current Measurement
Auxiliary Output:
Banana jacks on the front of the tester panel provide the
means for connecting an external, user-provided, multimeter for measurement of simulated fault current levels
produced by tester unit. Accuracy is dependent upon the
calibration standards and procedures employed during
calibration of the user supplied multimeter.
120 Vac, 3 A GFI duplex outlet provides 120 Vac threewire supply power for operation of low wattage devices
such as auxiliary measurement equipment, notebook
computers and supplementary lighting.
Protective Circuits
NOTE: Overloading of the 3 A rated GFI protected convenience outlet will result in complete shutdown of the
VFI tester device.
Ground Fault Protection
Interface Cables
Ground fault sensing capabilities enables automatic shut
down of the tester upon detection of a ground fault current within the tester or through the 120 Vac convenience
outlet on the tester front panel.
A set of two interface cables are provided with each VFI
tester unit. Each cable is 4.6 m (15 ft.) in length with connectors appropriate for the type of control and VFI unit
specified at time of order.
Internal Thermal Cutoff
VFI Tester automatically shuts off upon exceeding 65°C
(149°F) internal temperature. Cutoff resets upon internal
temperature cooling to below 50°C(122°F).
Side-Hinged VFI units with TPG controls utilize cable set
6A00393601. All VFI units with Tri-Phase controls and
Top-Hinged VFI units with TPG controls utilize cable set
6A00393501.
Automatic Shutdown
An automatic timer circuit turns off the tester if any control test exceeds five minutes in duration.
14-pin female to
14-pin male
Interrupter Interface Cable
Side-Hinged VFI w/TPG
Cable Set Part No. 6A00393601
AC Power Cord
19-pin male to
14-pin female
Control Interface Cable
A 2.3 m (7.5 ft.) 3-conductor power cord is provided.
Carrying Case
14-pin female to
18-pin recessed male
Interrupter Interface Cable
The VFI tester is housed in a high impact case with
detachable cover, and has a compartment for storing the
power cord and interconnecting cables.
Dimensions (Approximate)
318 mm (12.5”) High
432 mm (17”) Wide
432 mm (17”) Deep
All VFI w/Tri-Phase and
Top-Hinged VFI w/TPG
Cable Set Part No. 6A00393501
19-pin male to
18-pin female
Control Interface Cable
Figure 2.
Kyle® VFI Tester Cable Set Options
4
!
S285-10-7
SAFETY
FOR LIFE
DESCRIPTION OF TESTER
16
TO INTERRUPTER
B
1
A
K
L
C
J
P
M
D
H
N
E
F
VFI
EXTERNAL
TRIPPERS
G
INTERNAL
TRIPPERS
15
Tester
TO CONTROL
CONTROL
TEST
AØ
BØ
M
L
U
K
J
T
H
CØ
S
G
A
N
V
B
C
P
D
R
F
14
E
CURRENT
2
METER JACKS
TEST SELECT
13
PHASE SELECT
A-PHASE TRIPPER
17
12
3
B-PHASE TRIPPER
BATTERY
CONNECTOR
ON
18
30A
4
BATTERY TEST
ON
ON
19
60A
24
ON
20
21
120A
23
11
ON
C-PHASE TRIPPER
240A
10
TRIPPER TEST
2X
22
4-30A
1X
4-30A
25
5
TEST
6
RESET
9
CONTROL
TEST
INPUT
POWER
120 VAC
CONVENIENCE
OUTLET
120 VAC
Power Systems
8
7
Figure 3.
VFI Tester Front Panel
TABLE 1
Description and Functionality of VFI Tester Front Panel Features
Item No.
(Figure 3)
Description
Purpose and Use
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
VFI Cable Connector
Multi-meter Connection Jacks
Battery Test Terminals
Battery Test Switch
Power Switch
AC Power Receptacle
Cooling Fan Intake Port
Cooling Fan Exhaust Port
GFI Convenience Outlet
Tripper Test Switch
C-Phase Flux Shift Tripper
B-Phase Flux Shift Tripper
A-Phase Flux Shift Tripper
Control Cable Receptacle
Phase Select Switch
Testing Mode Selector Switch
17
18
19
20
21
22
23
24
25
LED Display
30 A Current Adder Switch
60 A Current Adder Switch
120 A Current Adder Switch
240 A Current Adder Switch
1X/2X Current Multiplier Switch
4-30 A Fault Current Rheostat
4-30 A Rheostat Enable Switch
Fault Test Switch
Interface for External VFI Switch Connector Cable
Measurement of Injection Current Levels
Interface for Battery Test cable
Initiates battery test
Energizes 120 Vac input to tester
Interface for 120Vac Power Cable
Unit Cooling
Unit Cooling
120 Vac, 3 A Ground Fault Protected Outlet for auxiliary power for meters, etc.
Verification of Internal Tripper Operation
Actuates when control board under test issues trip signal
Actuates when control board under test issues trip signal
Actuates when control board under test issues trip signal
Interface for Tri-Phase/TPG Control Test Cable
Selection of phase to be tested
Selection of either external test of flux-shift trippers within VFI unit under
test, internal self-check of flux-shift trippers within VFI tester, or general
Tri-phase/TPG Control Test Mode
Displays Test Data and Tester Status Information
Operation of switch adds 30 A of test current to total output of Tester Unit
Operation of switch adds 60 A of test current to total output of Tester Unit
Operation of switch adds 120 A of test current to total output of Tester Unit
Operation of switch adds 240 A of test current to total output of Tester Unit
Multiplies Designated Current Levels by a factor of two
Provides variable adder of 4-30 A Fault Current Level to total output of Tester Unit
Enables operation of 4-30 A Fault Current Rheostat (Item 23)
Initiates injection of simulated fault current to VFI control
5
VFI Tester Operating Instructions
OPERATING PROCEDURES
Tester operating procedures have been grouped three
functional groups; Control Tests, Flux-Shift Tripper Tests,
and Battery Tests.
Each group of tests is preceded by pre-test setup instructions which specify any required settings for the tester
and the device under test. Verify these settings before
starting any tests. Upon completion of testing, return the
control settings to the desired operating conditions
before returning the control to service.
NOTE: A 5 K ohm resistor is required to complete certain procedures detailed in this bulletin.
For specific information regarding the operation and
adjustment of Kyle ® Tri-Phase and TPG Controls refer to
Service Information Bulletin S285-75-1, Kyle Tri-Phase,
TPG, and TPG w/SCADA Electronic Control Installation
and Operation Instructions.
WARNING: Hazardous voltage. Always use a
shotgun stick when working with this equipment.
Failure to do so could result in contact with high voltage, which will cause death or severe personal injury.
!
G108A.0
WARNING: This equipment is not intended to
protect human life. Follow all locally approved
procedures and safety practices when installing or
operating this equipment. Failure to comply can result
in death, severe personal injury, and equipment damage.
G102.1
!
4. Connect the 19-pin male/14-pin female control interface cable (Item 2) to the VFI Tester at the Control
port.
WARNING: Hazardous voltage. Open the
switch associated with the control before attempting to disconnect its control cable. Failure to do so can
result in contact with high voltage pulse (300 V peak)
from the CT protection circuit, which can cause death
or severe personal injury.
T287.0
!
5. Break the connection between the control and VFI
unit by disconnecting the VFI control cable (Item 3)
from the male receptacle located on the outside of
the TPG control enclosure.
6. Connect the 14-pin male connector end of the tester
interrupter interface cable (Item 1) to the 14-pin
female end of the padmount cable (Item 3) originating from the front plate of the VFI unit under test.
7. Connect the 14-pin female connector end of the VFI
tester control interface cable (Item 2) to the male
receptacle of the TPG control enclosure.
8. Proceed with the testing procedures as detailed in
this service bulletin.
To return the unit under test to service:
1. Verify that the VFI Switches under test are in the
open position.
2. Turn off the VFI tester.
CAUTION: Equipment misoperation. This
device must be operated in dry environments
only. So not operate itw in rain, snow, or sleet. Failure
to comply can result in equipment misoperation and
possible personal injury.
G141.0
!
Testing In-Service VFI Units
The following procedures must be followed if an
in-service VFI padmounted switchgear unit is to be tested with the VFI tester apparatus.
14-pin female
connector at
cable end
14-pin male
connector at
cable end
TPG
Control
Enclosure
Item 3
VFI
Control
Cable
Side-Hinged Units with TPG Controls
1. Open the VFI Switches
2. Attach the power cable to the VFI tester and plug it
into a grounded, three-prong 120 Vac outlet.
Item 1
Interrupter
Interface
Cable
Item 2- Control
Interface Cable
VFI
TO INTERRUPTER
EXTERNAL
TRIPPERS
INTERNAL
TRIPPERS
TO CONTROL
Tester
CONTROL
TEST
Afl
Bfl
Cfl
19-pin male connector
at cable end
CURRENT
IMPORTANT: This device must be connected to a
properly grounded, 3-wire 120 Vac power source
to ensure safe and reliable operation. Do not operate
it using a “floating” power source such as a
portable generator.
METER JACKS
TEST SELECT
PHASE SELECT
A-PHASE TRIPPER
B-PHASE TRIPPER
BATTERY
CONNECTOR
14-pin female
connector at
cable end
ON
ON
ON
ON
30A
60A
120A
240A
C-PHASE TRIPPER
BATTERY TEST
ON
2X
4-30A
TRIPPER TEST
1X
4-30A
TEST
RESET
CONTROL
TEST
INPUT
POWER
120 VAC
3. Connect the 14-pin female/14-pin male interrupter
interface cable (Item 1) to the VFI Tester at the interrupter port. Refer to Figure 4 for steps 3 through 8.
6
Power Systems
CONVENIENCE
OUTLET
120 VAC
Figure 4.
Connection of the VFI Tester to side-hinged VFI
units with TPG controls.
!
S285-10-7
SAFETY
FOR LIFE
3. Disconnect the 14-pin female connector end of the
tester control interface cable (Item 2) from the TPG
control enclosure. Refer to Figure 4 for steps 3
through 8.
4. Disconnect the 14-pin male connector end of the VFI
tester interrupter interface cable (Item 1) from the 14pin female end of the VFI control cable (Item 3) originating from the front plate of the VFI unit under test.
CAUTION: Equipment misoperation. The capacitors
upon the Tri-phase and TPG boards will retain a
charge of 20 Vdc upon completion of control testing.
Apply a 5 k ohm resister between ground and the
P1-7, P1-5, and P1-3 board terminals for 10 seconds
prior to returning the control to service. Failure to comply can result in false tripping activity by the control
upon reinstallation.
T318.0
5. Reconnect the VFI control cable (Item 3) to the
receptacle located upon the TPG control enclosure
housing.
IMPORTANT: Always wear a grounding wrist strap
to control static electricity before handling circuit
boards. Attach wrist strap to ground terminal located
upon the front plate of the VFI unit. Failure to use this
strap may result in circuit board damage.
5. Break the connection between the control and VFI
unit by carefully disconnecting the internal VFI control wiring harness (Item 3) at the control.
6. Connect the 18-pin male connector end of the VFI
tester interrupter interface cable (Item 1) to the 18pin female end of the VFI control wire harness (Item
3).
7. Connect the 18-pin female connector end of the
tester control interface cable (Item 2) to the 18-pin
male header of the Tri-Phase/TPG board.
8. Proceed with the testing procedures as detailed within this service bulletin.
To return the unit under test to service:
6. Disconnect the interrupter and control interface
cables (Items 1 and 2) from the VFI tester and store
the cables in the storage compartment located in the
cover of the VFI tester.
1. Verify that the VFI Switches under test are in the
open position.
7. Close the VFI switches.
3. Disconnect the 18-pin female connector end of the
tester control interface cable (Item 2) from the 18-pin
male header of the Tri-Phase/TPG board. Refer to
Figure 5 for steps 3 through 7.
Top-Hinged VFI Units with TPG
Controls/All Tri-Phase Controls
1. Open the VFI Switches.
2. Attach the power cable to the VFI tester and plug it
into a grounded, three-prong 120 Vac outlet.
2. Turn off the VFI tester.
4. Disconnect the 18-pin male connector end of the
tester interrupter interface cable (Item 1) from the 18pin female end of the VFI control wire harness (Item
3).
IMPORTANT: This device must be connected to a
properly grounded, 3-wire 120 Vac power source
to ensure safe and reliable operation. Do not operate
it using a “floating” power source such as a
portable generator.
3. Connect the 14-pin female/18-pin male interrupter
interface cable (Item 1) to the VFI Tester at the interrupter port. Refer to Figure 5 for steps 3 through 8.
4. Connect the 19-pin male/18-pin female control interface cable (Item 2) to the VFI Tester at the control
port.
WARNING: Hazardous voltage. Open the
switch associated with the control before attempting to disconnect its control cable. Failure to do so can
result in contact with high voltage pulse (300 V peak)
from the CT protection circuit, which can cause death
or severe personal injury.
T287.0
!
CAUTION: Equipment damage. Use care while disconnecting and reconnecting cables to the TriPhase/TPG control. Do not misalign male and female
connectors or allow the full weight of the tester cable to
be transferred to the Tri-Phase/TPG board. Failure to
comply can result in damage to the board header and
possible equipment misoperation.
T319.0
Tri-Phase/
TPG Board
18-pin male
header
Item 3
VFI
Control
Wire
Harness
18-pin female
connector
18-pin female
connector
18-pin recessed
male connector
VFI
TO INTERRUPTER
B
A
L
C
M
D
P
N
E
F
EXTERNAL
TRIPPERS
INTERNAL
TRIPPERS
TO CONTROL
Tester
M
L
U
T
CONTROL
TEST
Afl
Bfl
A
N
V
S
P
R
Cfl
CURRENT
METER JACKS
TEST SELECT
Item 2
Control
Interface
Cable
PHASE SELECT
A-PHASE TRIPPER
Item 1
Interrupter
Interface
Cable
B-PHASE TRIPPER
BATTERY
CONNECTOR
ON
ON
ON
ON
30A
60A
120A
240A
C-PHASE TRIPPER
BATTERY TEST
ON
2X
4-30A
TRIPPER TEST
1X
4-30A
TEST
RESET
CONTROL
TEST
INPUT
POWER
120 VAC
Power Systems
CONVENIENCE
OUTLET
120 VAC
Figure 5.
Connection of VFI Tester to top-hinged VFI units
with TPG controls and all VFI units with Tri-Phase
controls.
7
VFI Tester Operating Instructions
CAUTION: Equipment misoperation. The capacitors
upon the Tri-phase and TPG boards will retain a
charge of 20 Vdc upon completion of control testing.
Apply a 5 k ohm resister between ground and the
P1-7, P1-5, and P1-3 board terminals for 10 seconds
prior to returning the control to service. Failure to comply can result in false tripping activity by the control
upon reinstallation.
T318.0
Note: Once a control test is initiated, pressing and
releasing the control test button a second time will result
in the test being aborted.
Battery tests can not be conducted during a control test.
Initial Tester Setup
5. Reconnect the VFI control wire harness (Item 3) to
the 18-pin male receptacle located upon the Triphase/TPG control.
Refer to Figure 3 for identification of individual VFI Tester
switches and other features referenced within the following setup procedures.
6. Disconnect the interrupter and control interface
cables (Items 1 and 2) from the VFI tester and store
the cables in the storage compartment located in the
cover of the VFI tester.
1. Connect the VFI tester to the VFI Padmount unit following the procedures described in the TESTING INSERVICE VFI UNITS section of this service bulletin.
7. Close the VFI switches.
2. Connect external multi-meter to the multi-meter
tester connection jacks and set external meter to
appropriate current measurement range.
3. Energize the tester by setting the power switch to ON.
Control Tests
The VFI tester enables testing and verification of minimum trip timing values for each phase of the VFI unit.
Testing at nominal test current values of 150, 300 and
1000 percent of minimum trip current levels verifies Triphase/TPG board response at current levels typically
requiring slow, medium and fast trip operations.
Current
Adder
Switches
ON
ON
ON
ON
30A
60A
120A
240A
Conduct Internal Flux-Shift Tripper Test
The internal VFI Tester flux-shift trippers should be tested for correct operation at the beginning of every control
testing session. Failure to verify the correct operation of
the internal flux-shift trippers prior to a control test could
result in an erroneous assessment of control performance, in the event of a malfunction of the internal VFI
Tester flux-shift trippers.
Verify the internal flux-shift trippers are operational with the
following procedure:
1. Depress all three internal flux-shift trippers. Refer to
Figure 3 for steps 1 through 8.
ON
2X
2. Place the Test Selector Switch into the INTERNAL
TRIPPERS position.
4-30A
1X
3. Place the Phase Selector Switch into the A-PHASE
position.
4-30A Rheostat
Enable Switch
4-30A Rheostat
4-30A
1X/2X Current
Multiplier Switch
CONTROL
TEST
Figure 6.
VFI Tester Current Adjustment Switches
Test current values are set by selectively closing a group
of toggle switches controlling a stepped network of resistors within the VFI tester unit (Figure 6). Placing the
4-30 A toggle switch into the ON position enables operation of a 4-30 A fine adjustment rheostat for precise
adjustment of test current levels.
Pressing the Control Test button of the VFI tester initiates
injection of simulated fault current into the Tri-Phase/TPG
control board and concurrently begins measurement of
the accrued time between test initialization and and
issuance of a trip signal. Upon issuance of a trip signal,
the flux-shift tripper of the respective phase being tested
8
should operate as the LCD display indicates the accrued
trip-time interval.
4. Press and release the Tripper Test button. The APhase flux-shift tripper on the VFI tester should operate immediately.
5. Place the Phase Selector Switch into the B-PHASE
position.
6. Press and release the Tripper Test button to initiate
the test. The B-Phase flux-shift tripper on the VFI
tester should operate immediately.
7. Place the Phase Selector Switch into the C-PHASE
position.
8. Press and release the Tripper Test button to initiate
the test. The C-Phase flux-shift tripper on the VFI
tester should operate immediately.
8. Depress all of the flux-shift trippers on the VFI tester.
Upon completion of the internal Flux-Shift Tripper Test,
complete the initial set-up procedure as follows:
1. Place the Test Select switch into the CONTROL
TEST position.
2. Place the Phase Select switch into the A-PHASE
position.
!
S285-10-7
SAFETY
FOR LIFE
Initial Tri-phase/TPG Control Setup
IMPORTANT: Always wear a grounding wrist strap
to control static electricity before handling circuit
boards. Attach wrist strap to ground terminal located
upon the front plate of the VFI unit. Failure to use this
strap may result in circuit board damage.
Refer to Figures 9 and 10 for locations of individual control switches referenced within the following procedures.
1. Set the minimum trip levels on A-phase, B-phase,
and C-phase to 50 A.
2. Set the control board for Single Phase/Independent
Trip.
Instantaneous Trip Test - Ground
(TPG only)
Setup:
1. Verify that the settings of the tester and control are as
described in the Initial Tester Setup and Initial Triphase/TPG Control Setup sections of this bulletin.
2. Place the Ground Trip Block switch on the control
board in the OFF position.
3. Place the Ground Instantaneous Trip switch on the
control board into the ON position.
Test Procedure:
3. Set the Ground Trip level to 50 A (TPG only).
1. Set the minimum trip levels on A-, B-, and C-phase to
690 A while maintaining the Ground Trip level setting
at 50 A.
4. Set the Ground Trip Block Switch in the ON position
(TPG only).
2. Turn the 4-30 A rheostat adjusting knob fully counterclockwise.
Instantaneous Trip Test - Phase
Setup
1. Verify that the settings of the tester and control are as
described in the Initial Tester Setup and Initial Triphase/TPG Control Setup sections of this bulletin.
2. Place the Phase Instantaneous Trip switch on the
control board into the ON position.
Test Procedure
VFI Tester Operation:
1. Place the 4-30 A and 30 A Fault Current toggle
switches into the ON position.
2. Turn the 4-30 A rheostat adjusting knob fully counterclockwise.
3. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
4. Slowly turn the 4-30 A rheostat adjusting knob clockwise while monitoring the current value on the multimeter. Verify that the A-Phase flux-shift tripper on the
VFI tester operates when the fault current exceeds
50 A.
5. Place the Phase Select switch into the B-PHASE
position.
3. Place the Phase Select Switch into the A-PHASE
position.
4. Turn the 4-30 A rheostat adjusting knob fully counterclockwise.
5. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
6. Slowly turn the 4-30 A rheostat adjusting knob clockwise while monitoring the current value on the multimeter.
7. Verify that the A-Phase, B-Phase, and C-Phase fluxshift trippers on the VFI tester operate when the fault
current exceeds 50 A.
8. Depress the flux-shift trippers for all three phases.
9. Place the Phase Select Switch to the B-PHASE position.
10. Repeat steps 2 through 7.
11. Place the Phase Select Switch to the C-PHASE position.
12. Repeat steps 2 through 7.
13. Return the minimum trip levels on A-Phase, BPhase, and C-Phase on the control board to 50 A.
6. Repeat steps 2 through 4.
14. Place the Ground Trip Block switch on the control
board to the ON position.
7. Place the Phase Select switch into the C-PHASE
position.
15. Place the Ground Instantaneous Trip switch on the
control board into the OFF position.
8. Repeat steps 2 through 4.
Time Current Curve (TCC) Trip Test Phase
9. Return the Phase Instantaneous Trip switch on the
control board into the OFF position.
CAUTION: Equipment misoperation. The capacitors
upon the Tri-phase and TPG boards will retain a charge
of 20 Vdc upon completion of control testing. Apply a
5 k ohm resister between ground and the
P1-7, P1-5, and P1-3 board terminals for 10 seconds
prior to returning the control to service. Failure to comply can result in false tripping activity by the control
upon reinstallation.
T318.0
Setup – 150% of minimum trip - Phase:
1. Verify that the settings of the tester and control are as
described in the Initial Tester Setup and Initial Triphase/TPG Control Setup sections of this bulletin.
2. Place the 4-30 A and 60 A Fault Current switches on
the VFI tester into the ON position. All other Fault
Current switches should be in the OFF position.
9
VFI Tester Operating Instructions
3. Place the Phase Select Switch on the VFI tester into
the A-PHASE position.
6. Press and release the Control Test button to terminate flow of simulated fault current to the control.
4. Set the minimum trip level for A-Phase on the control
board to 690 A. This prevents the control from issuing a trip signal when calibrating the fault current.
7. Set the minimum trip level for A-Phase on the control
board to 50 A.
5. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
6. While monitoring the fault current on the multimeter,
adjust the 4-30 A rheostat adjusting knob until the
multimeter reads 75 mA ± 5 mA.
7. Press and release the Control Test button to terminate flow of simulated fault current to the control.
8. Set the minimum trip level for A-Phase on the control
board to 50 A.
Test Procedure – 150% of minimum trip - Phase:
The Phase Minimum-Trip test is performed as follows:
1. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
2. Upon operation of the flux-shift tripper record the
time displayed on the LCD, and compare it with the
150% entry in Table 2 for the timing card that is used
in the control board.
3. Place the Phase Select switch into the B-PHASE
position. Repeat steps 2 and 3.
4. Place the Phase Select Switch on the VFI tester into
the C-PHASE position. Repeat steps 2 and 3.
Test Procedure – 300% of minimum trip - Phase:
1. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
2. Upon operation of the flux-shift tripper record the
time displayed on the LCD, and compare it with the
300% entry in Table 2 for the timing card that is used
in the control board.
3. Place the Phase Select switch into the B-PHASE
position. Repeat steps 2 and 3.
4. Place the Phase Select Switch on the VFI tester into
the C-PHASE position. Repeat steps 2 and 3.
Setup – 1000% of minimum trip - Phase:
1. Place the 4-30 A, 240 A Fault Current switches on the
VFI tester into the ON position, and the 1X/2X Fault
Current switch on the VFI tester into the 2X position.
All other Fault Current switches should be in the OFF
position.
2. Place the Phase Select Switch on the VFI tester into
the A-PHASE position.
3. Set the minimum trip level for A-Phase on the control
board to 690 A. This prevents the control from issuing a trip signal when calibrating the fault current.
4. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
Setup – 300% of minimum trip - Phase:
1. Place the 4-30 A and 120 A Fault Current switches on
the VFI tester into the ON position. All other Fault
Current switches should be in the OFF position.
2. Place the Phase Select Switch on the VFI tester into
the A-PHASE position.
3. Set the minimum trip level for A-Phase on the control
board to 690 A. This prevents the control from issuing a trip signal when calibrating the fault current.
4. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
5. While monitoring the fault current on the multimeter,
adjust the 4-30 A rheostat adjusting knob until the
multimeter reads 150 mA ± mA.
5. While monitoring the fault current on the multimeter,
adjust the 4-30 A rheostat adjusting knob until the
multimeter reads 500 mA ± 35 mA.
7. Press and release the Control Test button to terminate flow of simulated fault current to the control.
8. Set the minimum trip level for A-Phase on the control
board to 50 A.
Test Procedure – 1000% of minimum trip - Phase:
1. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
2. Upon operation of the flux-shift tripper record the
time displayed on the LCD, and compare it with the
TABLE 2
Acceptable Control Response Time Range for TCC Tests
Acceptable Control Response Time Range for TCC Tests
Percentage of
Test Current
EF
Curve
KF
Curve
TF
Curve
H
Curve
F
Curve
150%
3.484-6.461 sec
16.632-43.509 sec
23.696-47.054 sec
2.023-3.182 sec
2.200-3.361 sec
300%
0.532-0.838 sec
0.586-0.895 sec
1.645-2.863 sec
0.441-0.726 sec
0.476-0.762 sec
1000%
0.058-0.087 sec
0.038-0.070 sec
0.193-0.279 sec
0.032-0.052 sec
0.112-0.132 sec
* NOTE: These timing ranges represent ± 10% in current or time, or ±10ms, whichever is greater.
10
!
S285-10-7
SAFETY
FOR LIFE
300% entry in Table 2 for the timing card that is used
in the control board.
3. Set the minimum trip level on the A-, B-, and CPhases of the control board to 690 A.
3. Place the Phase Select switch into the B-PHASE
position. Repeat steps 2 and 3.
4. Place the 4-30 A and 120 A Fault Current switches on
the VFI tester into the ON position. All other Fault
Current switches should be in the OFF position.
4. Place the Phase Select Switch on the VFI tester into
the C-PHASE position. Repeat steps 2 and 3.
Ground-Minimum Trip Test – TPG Only
Setup – 150% of minimum trip - Ground (TPG Only):
1. Verify that the settings of the tester and control are as
described in the Initial Tester Setup and Initial Triphase/TPG Control Setup sections of this bulletin.
5. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
6. While monitoring the fault current on the multimeter,
adjust the 4-30 A rheostat adjusting knob until the
multimeter reads 150 mA ± 10 mA.
7. Press and release the Control Test button to terminate flow of simulated fault current to the control.
2. Place the Ground Trip Block switch on the control
board into the OFF position.
8. Set the minimum trip level for Ground on the control
board to 50 A.
3. Set the minimum trip level on the A-, B-, and CPhases of the control board to 690 A.
Test Procedure – 300% of minimum trip – Ground
(TPG only):
4. Place the 4-30 A and 60 A Fault Current switches on
the VFI tester into the ON position. All other Fault
Current switches should be in the OFF position.
5. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
6. While monitoring the fault current on the multimeter,
adjust the 4-30 A rheostat adjusting knob until the
multimeter reads 75 mA ± 5 mA.
7. Press and release the Control Test button to terminate flow of simulated fault current to the control.
8. Set the minimum trip level for Ground on the control
board to 50 A.
Test Procedure – 150% of minimum trip – Ground
(TPG only)
1. Place the Phase Select Switch on the VFI tester into
the A-PHASE position.
2. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
3. When the control board issues a trip signal, the A-, Band C-Phase flux-shift trippers should operate, and
the timer will stop.
4. Record the time displayed on the LCD, and compare
it with the 150% entry in Table 2 for the timing card
that is used in the control board.
5. Depress the flux-shift trippers for all three phases.
6. Place the Phase Select switch into the B-PHASE
position.
7. Repeat steps 2 through 5.
8. Place the Phase Select switch into the C-PHASE
position.
9. Repeat steps 2 through 5.
Setup – 300% of minimum trip – Ground (TPG only):
1. Verify that the settings of the tester and control are as
described in the Initial Tester Setup and Initial Triphase/TPG Control Setup sections of this bulletin.
2. Place the Ground Trip Block switch on the control
board into the OFF position.
1. Place the Phase Select Switch into the A-PHASE
position.
2. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
3. When the control board issues a trip signal, the APhase, B-Phase, and C-Phase flux-shift trippers
should operate, and the timer will stop.
4. Record the time displayed on the LCD, and compare
it with the 300% entry in Table 2 for the timing card
that is used in the control board.
5. Depress the flux-shift trippers for all three phases.
6. Place the Phase Select switch into the B-PHASE
position.
7. Repeat steps 2 through 5.
8. Place the Phase Select switch into the C-PHASE
position.
9. Repeat steps 2 through 5.
Setup – 1000% of minimum trip - Ground: (TPG only)
1. Verify that the settings of the tester and control are as
described in the Initial Tester Setup and Initial Triphase/TPG Control Setup sections of this bulletin.
2. Place the Ground Trip Block switch on the control
board into the OFF position.
3. Set the minimum trip level on the A-, B-, and CPhases of the control board to 690 A.
4. Place the 4-30 A, and 240 A Fault Current switches on
the VFI tester into the ON position, and the 1X/2X
Fault Current switch on the VFI tester into the 2X
position. All other Fault Current switches should be in
the OFF position.
5. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
6. While monitoring the fault current on the multimeter,
adjust the 4-30 A rheostat adjusting knob until the
multimeter reads 500 mA ± 35 mA.
7. Press and release the Control Test button to terminate flow of simulated fault current to the control.
8. Set the minimum trip level for Ground on the control
board to 50 A.
11
VFI Tester Operating Instructions
Test Procedure – 1000% of minimum trip – Ground
(TPG only):
1. Place the Phase Select Switch into the A-PHASE
position.
2. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
3. When the control board issues a trip signal, the APhase, B-Phase, and C-Phase flux-shift trippers
should operate, and the timer will stop.
4. Record the time displayed on the LCD, and compare
it with the 1000% entry in Table 2 for the timing card
that is used in the control board.
5. Depress the flux-shift trippers for all three phases.
6. Place the Phase Select switch into the B-PHASE
position.
7. Repeat steps 2 through 5.
8. Place the Phase Select switch into the C-PHASE
position.
9. Repeat steps 2 through 5.
CAUTION: Equipment misoperation. The capacitors
upon the Tri-phase and TPG boards will retain a
charge of 20 Vdc upon completion of control testing.
Apply a 5 k ohm resister between ground and the
P1-7, P1-5, and P1-3 board terminals for 10 seconds
prior to returning the control to service. Failure to comply can result in false tripping activity by the control
upon reinstallation.
T318.0
SCADA Board Tests –TPG
4. Place the 30 A Fault Current switch into the ON position. Place all of the other Fault Current switches into
the OFF position.
5. Reset the target by pressing the Control Test button,
waiting 5 seconds, and then pressing the Control
Test button again. The A-Phase Fault Target should
now be black.
6. Place the Phase Select switch into the B-PHASE
position.
7. Repeat steps 1 and 2.
8. After the B-Phase flux-shift tripper operates, verify
that the B-Phase Fault Target on the SCADA board is
orange.
9. Place the 30 A Fault Current toggle switch into the
ON position. Place all of the other Fault Current
switches into the OFF position.
10. Reset the target by pressing the Control Test button,
waiting 5 seconds, and then pressing the Control
Test button again. The B-Phase Fault Target should
now be black.
11. Place the Phase Select switch into the C-PHASE
position.
12. Repeat steps 1 and 2.
13. After the C-Phase flux-shift tripper operates, verify
that the C-Phase Fault Target on the SCADA board
is orange.
14. Place the 30 A Fault Current switch into the ON position. Place all of the other Fault Current switches into
the OFF position.
Refer to Figure 11 for identification of individual SCADA
accessory board components referenced within the following procedures.
15. Reset the target by pressing the Control Test button,
waiting 5 seconds, and then pressing the Control
Test button again. The C-Phase Fault Target should
now be black.
IMPORTANT: Always wear a grounding wrist strap
to control static electricity before handling circuit
boards. Attach wrist strap to ground terminal located
upon the front plate of the VFI unit. Failure to use this
strap may result in circuit board damage.
16. Place the Ground Trip Block switch into the OFF
position (TPG only).
17. Set the minimum trip levels on A-phase, B-phase,
and C-phase to 690 A.
18. Reset the flux-shift trippers.
Fault Target Test
19. Repeat steps 1 and 2.
Setup
20. After all three of the flux-shift trippers operate, verify
that the Ground Fault Target on the SCADA board is
orange.
1. Verify that the settings of the tester and control are as
described in the Initial Tester Setup and Initial Triphase/TPG Control Setup sections of this bulletin.
2. Place the Phase Instantaneous Trip switch on the
control board into the ON position.
Test Procedure
1. Place the 60 A Fault Current switch into the ON position. Place all of the other Fault Current switches into
the OFF position.
2. Press and release the Control Test button to initiate
the test.
3. After the A-Phase flux-shift tripper operates, verify
that the A-Phase Fault Target on the SCADA board is
orange.
12
21. Place the 30 A Fault Current switch into the ON position. Place all of the other Fault Current switches into
the OFF position.
22. Press and release the Control Test button, wait 5
seconds, then press and release the Control Test
button again. The C-Phase Fault Target should now
be black.
23. Place the Ground Trip Block switch into the ON position (TPG only).
24. Reset the flux-shift trippers.
!
SAFETY
FOR LIFE
Emergency Minimum Trip Multiplier
Test
S285-10-7
Control Setup – 5X minimum trip multiplier test
(250 A)
1. Verify that the settings of the tester and control are as
described in the Initial Tester Setup and Initial Triphase/TPG Control Setup sections of this bulletin.
1. Set the emergency trip multiplier switches for APhase, B-Phase, and C-Phase for ‘5X’ (.8X + 3.2X
+1X default).
TPG Control Setup – 2X minimum trip multiplier test
(100 A)
Test Procedure – 5X minimum trip multiplier test
250 A)
1. Place the Phase Instantaneous Trip switch into the
ON position.
1. Place the 4-30 A and 240 A Fault Current switches on
the VFI tester into the ON position. All other Fault
Current switches should be in the OFF position.
2. Set the emergency trip multiplier switches for APhase, B-Phase, and C-Phase for 2X (.2X + .8X +1X
default).
2. Turn the 4-30 A rheostat adjusting knob fully counterclockwise.
Test Procedure – 2X minimum trip multiplier test
(100 A)
3. Place the Phase Select Switch on the VFI tester into
the A-Phase position.
1. Place the 4-30 A, 30 A, and 60 A Fault Current toggle
switches on the VFI tester into the ON position. All
other Fault Current switches should be in the OFF
position.
4. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
2. Turn the 4-30 A rheostat adjusting knob fully counterclockwise.
3. Place the Phase Select Switch on the VFI tester into
the A-PHASE position.
4. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
5. Slowly turn the 4-30 A rheostat adjusting knob clockwise while monitoring the current value on the multimeter. Verify that the A-Phase flux-shift tripper on the
VFI tester operates when the fault current exceeds
100 A (2X the minimum trip setting of 50 A).
6. Turn the 4-30 A rheostat adjusting knob fully counterclockwise.
7. Place the Phase Select Switch on the VFI tester into
the B-PHASE position.
8. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
9. Slowly turn the 4-30 A rheostat adjusting knob clockwise while monitoring the current value on the multimeter. Verify that the B-Phase flux-shift tripper on
the VFI tester operates when the fault current
exceeds 100 A (2X the minimum trip setting of 50 A).
10. Turn the 4-30 A rheostat adjusting knob fully counterclockwise.
11. Place the Phase Select Switch on the VFI tester into
the C-PHASE position.
12. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
13. Slowly turn the 4-30 A rheostat adjusting knob clockwise while monitoring the current value on the multimeter. Verify that the C-Phase flux-shift tripper on
the VFI tester operates when the fault current
exceeds 100 A (2X the minimum trip setting of 50 A).
5. Slowly turn the 4-30 A rheostat adjusting knob clockwise while monitoring the current value on the multimeter. Verify that the A-Phase flux-shift tripper on the
VFI tester operates when the fault current exceeds
250 A (5X the minimum trip setting of 50 A).
6. Turn the 4-30 A rheostat adjusting knob fully counterclockwise.
7. Place the Phase Select Switch on the VFI tester into
the B-Phase position.
8. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
9. Slowly turn the 4-30 A rheostat adjusting knob clockwise while monitoring the current value on the multimeter. Verify that the B-Phase flux-shift tripper on
the VFI tester operates when the fault current
exceeds 250 A (5X the minimum trip setting of 50 A).
10. Turn the 4-30 A rheostat adjusting knob fully counterclockwise.
11. Place the Phase Select Switch on the VFI tester into
the C-Phase position.
12. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
13. Slowly turn the 4-30 A rheostat adjusting knob clockwise while monitoring the current value on the multimeter. Verify that the C-Phase flux-shift tripper on
the VFI tester operates when the fault current
exceeds 250 A (5X the minimum trip setting of 50 A).
CAUTION: Equipment misoperation. The capacitors
upon the Tri-phase and TPG boards will retain a
charge of 20 Vdc upon completion of control testing.
Apply a 5 k ohm resister between ground and the
P1-7, P1-5, and P1-3 board terminals for 10 seconds
prior to returning the control to service. Failure to comply can result in false tripping activity by the control
upon reinstallation.
T318.0
13
VFI Tester Operating Instructions
Inrush Restraint Tests
1. Verify that the settings of the tester and control are as
described in the Initial Tester Setup and Initial Triphase/TPG Control Setup sections of this bulletin.
Control Setup – 2X minimum trip multiplier during
inrush (100 A), 1 second reset time
1. Set the Phase Instantaneous Trip switch into the ON
position.
2. Place the Inrush Restraint switch into the ON position.
17. Depress the B-Phase flux-shift tripper.
18. Place the 120 A Fault Current switch into the OFF
position.
19. Place the Phase Select Switch on the VFI tester into
the C-PHASE position.
20. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
21. Verify that the C-Phase flux-shift tripper on the VFI
tester operates after 1 second ± 10%.
22. Depress the C-Phase flux-shift tripper.
3. Place the Ground Trip Block During Inrush switch
into the ON position.
23. Place the 120 A Fault Current switch into the ON
position.
4. Set the A-Phase, B-Phase, and C-Phase Inrush
Restraint Minimum Trip Multiplier switches for 2X (1X
+ 1X default setting).
24. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
5. Set the Reset Time switches for 1 seconds (.5 sec +
.5 sec default setting).
6. Place the 4-30 A, 30 A, and 60 A Fault Current
switches on the VFI tester into the ON position. All
other Fault Current switches should be in the OFF
position.
Test Procedure – 2X minimum trip multiplier during
inrush (100 A), 1 second reset time
1. Place the Phase Select Switch on the VFI tester into
the A-PHASE position.
2. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
3. Verify that the A-Phase flux-shift tripper on the VFI
tester operates after 1 second ± 10%.
4. Depress the A-Phase flux-shift tripper.
5. Place the 120 A Fault Current switch into the ON
position.
6. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
7. Verify that the A-Phase flux-shift tripper on the VFI
tester operates immediately.
8. Depress the A-Phase flux-shift trippers.
9. Place the 120 A Fault Current switch into the OFF
position.
10. Place the Phase Select Switch on the VFI tester into
the B-PHASE position.
11. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
12. Verify that the B-Phase flux-shift tripper on the VFI
tester operates after 1 second ± 10%.
13. Depress the B-Phase flux-shift trippers.
14. Place the 120 A Fault Current switch into the ON
position.
15. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
16. Verify that the B-Phase flux-shift tripper on the VFI
tester operates immediately.
14
25. Verify that the C-Phase flux-shift tripper on the VFI
tester operates immediately.
26. Depress the C-Phase flux-shift tripper.
27. Place the 120 A Fault Current switch into the OFF
position.
Control Setup – 5X minimum trip multiplier during
inrush (250 A), 3 second reset time
1. Set the A-Phase, B-Phase, and C-Phase Inrush
Restraint Minimum. Trip Multiplier switches for 5X
(4X + 1X default setting).
2. Set the Reset Time switches for 3 seconds (.5 sec +
2 sec + .5 sec default setting).
3. Place the 240 A Fault Current switch on the VFI
tester into the ON position. All other Fault Current
switches should be in the OFF position.
Test Procedure – 5X minimum trip multiplier during
inrush (250 A), 3 second reset time
1. Place the Phase Select Switch on the VFI tester into
the A-PHASE position.
2. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
3. Verify that the A-Phase flux-shift tripper on the VFI
tester operates after 3 seconds ± 10%.
4. Depress the A-Phase flux-shift tripper.
5. Place the 30 A Fault Current switch into the ON position. All other Fault Current switches should be in the
OFF position.
6. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
7. Verify that the A-Phase flux-shift tripper on the VFI
tester operates immediately.
8. Depress the A-Phase flux-shift tripper.
9. Place the 120 A Fault Current switch into the OFF
position.
10. Place the Phase Select Switch on the VFI tester into
the B-PHASE position.
11. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
!
S285-10-7
SAFETY
FOR LIFE
12. Verify that the B-Phase flux-shift tripper on the VFI
tester operates after 1 second ± 10%.
13. Depress the B-Phase flux-shift tripper.
14. Place the 30 A Fault Current switch into the ON position. All other Fault Current switches should be in the
OFF position.
15. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
16. Verify that the B-Phase flux-shift tripper on the VFI
tester operates immediately.
17. Depress the B-Phase flux-shift tripper.
4. Verify that the A-Phase, B-Phase, and C-Phase fluxshift trippers on the VFI tester all operate within
50 ms of the fault current being applied.
SCADA Board Customer Connections
Tests (TPG only)
The following materials are required for SCADA board
testing; small flat-blade screwdriver; Fluke 87 Multimeter
or equivalent; 3” jumper wire; Ac power cord with wire
ends stripped.
1. Verify that the settings of the tester and control are as
described in the Initial Tester Setup and Initial Triphase/TPG Control Setup sections of this bulletin.
18. Place the 120 A Fault Current switch into the OFF
position.
Minimum Trip Multiplier Enable Readback Status Test
19. Place the Phase Select Switch on the VFI tester into
the C-PHASE position.
1. Place the Minimum Trip Multiplier switch into the
INCREASED position. Refer to Figure 11.
20. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
2. Using the multimeter, verify continuity between pin 8
and 18 of the Customer Connections Terminal Block.
21. Verify that the C-Phase flux-shift tripper on the VFI
tester operates after 3 seconds ± 10%.
3. Place the Minimum Trip Multiplier switch into the
NORMAL position. Refer to Figure 11.
22. Depress the C-Phase flux-shift tripper.
4. Using the multimeter, verify non-continuity between
pins 8 and 18 of the Customer Connections Terminal
Block.
23. Place the 30 A Fault Current switch into the ON position. All other Fault Current switches should be in the
OFF position.
Ground Trip Block Enable Readback Status Test
24. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
1. Place the Ground Trip Block switch into the ON position.
25. Verify that the C-Phase flux-shift tripper on the VFI
tester operates immediately.
2. Using the multimeter, verify continuity between pin 8
and 17 of the Customer Connections Terminal Block.
26. Depress the C-Phase flux-shift tripper.
3. Place the Minimum Trip Multiplier switch into the
NORMAL position.
27. Place the 120 A Fault Current switch into the OFF
position.
Control Setup – Ground Fault Trip during Inrush test
1. Set the minimum trip levels on A-Phase, B-Phase, CPhase, and Ground to 50 A.
2. Place the Ground Trip Block switch into the OFF
position.
3. Place the Phase and Ground Instantaneous Trip
switches into the ON position.
4. Place the Ground Trip Block During Inrush switch
into the OFF position.
5. Place the Inrush Restraint switch into the ON position.
6. Set the A-Phase, B-Phase, and C-Phase Inrush
Restraint Minimum Trip Multiplier switches for 5X (4X
+ 1X default setting).
Test Procedure – Ground Fault Trip during Inrush test
1. Place the 120 A Fault Current switch on the VFI
tester into the ON position. All other Fault Current
switches should be in the OFF position.
4. Using the multimeter, verify non-continuity between
pins 8 and 17 of the Customer Connections Terminal
Block.
Target Readback Status Test
Setup
1. Place the Phase Instantaneous Trip switch on the
control board into ON position.
Test Procedure
1. Place the 60 A Fault Current toggle switch into the
ON position. Place all of the other Fault Current
switches into the OFF position.
2. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
3. After the A-Phase flux-shift tripper operates, verify
continuity between pins 8 and 9 of the Customer
Connections Terminal Block.
2. Place the Phase Select Switch on the VFI tester into
the A-PHASE position.
4. Using a jumper wire, temporarily jumper pins 13 and
14 of the Customer Connections Terminal Block.
This will reset all of the fault targets. Verify non-continuity between pins 8 and 9 of the Customer
Connections Terminal Block.
3. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
5. Place the Phase Select switch into the B-PHASE
position.
15
VFI Tester Operating Instructions
6. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
7. After the B-Phase flux-shift tripper operates, verify
continuity between pins 8 and 10 of the Customer
Connections Terminal Block.
8. Using a jumper wire, temporarily jumper pins 13 and
14 of the Customer Connections Terminal Block.
This will reset all of the fault targets. Verify non-continuity between pins 8 and 10 of the Customer
Connections Terminal Block.
9. Place the Phase Select switch into the C-PHASE
position.
10. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
11. After the C-Phase flux-shift tripper operates, verify
continuity between pins 8 and 11 of the Customer
Connections Terminal Block.
12. Using a jumper wire, temporarily jumper pins 13 and
14 of the Customer Connections Terminal Block.
This will reset all of the fault targets. Verify non-continuity between pins 8 and 11 of the Customer
Connections Terminal Block.
13. Place the Ground Trip Block switch into the OFF
position (TPG only).
Remote Trip Test
Setup
1. Place the remote trip power selector switch into the
125 VDC/120 VAC position.
2. Using a power cord, apply 120 Vac to pins 6 and 7
of the Customer Connections terminal block located
upon the SCADA board. Connect the hot wire to
pin 6. Connect the neutral wire to pin 7.
IMPORTANT: The TPG/SCADA board accessory is
a polarity dependent device. Do not connect a hot
wire to the terminal 7 of the customer connections terminal block of the SCADA board. Failure to comply
will result in damage to the SCADA board. Refer to
the connections decal found within the control enclosure for additional information.
3. Plug the other end of the power cord into the accessory outlet on the VFI tester.
Test Procedure
1. Reset the flux-shift trippers on VFI tester.
2. Using a jumper wire, jumper pins 1 and 4 of the
Customer Connections Terminal Block.
15. Reset the flux-shift tripper.
3. Using another jumper wire, momentarily jumper pins
5 and 15 of the Customer Connections Terminal
Block. The A-Phase flux-shift tripper on the VFI
tester should operate.
16. Press and release the Control Test button to initiate
flow of simulated fault current to the control.
4. Remove the jumper wire from pins 1 and 4 of the
Customer Connections terminal block.
17. After all three of the flux-shift trippers operate, verify
continuity between pins 8 and 12 of the Customer
Connections Terminal Block.
5. Using the jumper wire, jumper pins 2 and 4 of the
Customer Connections terminal block.
14. Set the minimum trip levels on A-phase, B-phase,
and C-phase to 690 A.
18. Using a jumper wire, temporarily jumper pins 13 and
14 of the Customer Connections Terminal Block.
This will reset all of the fault targets. Verify non-continuity between pins 8 and 12 of the Customer
Connections Terminal Block.
6. Using another jumper wire, momentarily jumper pins
5 and 15 of the Customer Connections Terminal
Block. The B-Phase flux-shift tripper on the VFI
tester should operate.
7. Remove the jumper wire from pins 2 and 4 of the
Customer Connections Terminal Block.
19. Place the Ground Trip Block switch into the OFF
position (TPG only).
8. Using the jumper wire, jumper pins 3 and 4 of the
Customer Connections Terminal Block.
20. Reset the flux-shift tripper.
9. Using another jumper wire, momentarily jumper pins
5 and 15 of the Customer Connections Terminal
Block. The C-Phase flux-shift tripper on the VFI
tester should operate.
Ground Trip Block Enable Test
1. Verify non-continuity between pins 8 and 17 of the
Customer Connections Terminal Block.
2. Using a jumper wire, jumper pins 15 and 16 of the
Customer Connections Terminal Block.
3. Verify continuity between pins 8 and 17 of the
Customer Connections Terminal Block.
4. Remove the jumper wire between pins 15 and 16 of
Customer Connections Terminal Block.
5. Verify non-continuity between pins 8 and 17 of the
Customer Connections Terminal Block.
16
10. Remove the jumper wire from pins 3 and 4 of the
Customer Connections Terminal Block.
11. Reset the flux-shift trippers.
!
S285-10-7
SAFETY
FOR LIFE
External Flux-Shift Tripper Tests
The External Flux-Shift Tripper Test verifies the operation
of the flux-shift trippers contained within the VFI
switchgear under test. It should be used as a final diagnostic procedure only after verifying the control is operating correctly through administration of the control tests
detailed in the Operating Procedures section of this service bulletin.
IMPORTANT
If service conditions allow, the VFI unit should be
removed from service by disconnecting all sources of
system voltage. If it is not possible to remove the VFI
device from service by disconnecting all sources of system voltage, follow the procedures and safety precautions detailed in the TESTING IN-SERVICE VFI UNITS
section found on page 6 of this service bulletin.
WARNING: Hazardous voltage. Disconnect all
source and tap elbows prior to conducting an
external flux-shift tripper test. Failure to comply can
result in possible contact with high voltage resulting in
death or severe personal injury.
T320.0
!
WARNING: Hazardous voltage. Always use a
shotgun stick when working with this equipment.
Failure to do so could result in contact with high voltage, which will cause death or severe personal injury.
10. Place the Phase Selector switch into the B-PHASE
position.
11. Press the Tripper Test button. The B-Phase flux-shift
tripper in the padmount unit should operate immediately.
12. Place the Phase Selector switch into the C-PHASE
position.
13. Press the Tripper Test button. The C-Phase flux-shift
tripper in the padmount unit should operate immediately.
14. De-energize the tester by setting the power switch to
OFF.
15. Disconnect the 14-pin male connector end of the
tester interrupter interface cable (Item 1) from the 14pin female end of the padmount cable (Item 2) originating from the front plate of the VFI unit under test.
16. Reconnect the VFI control cable (Item 2) to the
receptacle located upon the TPG control enclosure.
17. Disconnect the interrupter and control interface cable
(Item 1) from the VFI tester and store the cable in the
storage compartment located in the cover of the VFI
tester.
18. Using a hotstick, close in all three phases on the padmount unit.
!
G108A.0
Side-Hinged Units with TPG Controls
1. Remove the padmount unit from service.
2. Attach the power cable to the VFI tester and plug it
into a grounded, three-prong 120 Vac outlet.
14-pin male
connector at
cable end
TPG
Control
Enclosure
Item 2
VFI
Control
Cable
3. Connect the 14-pin female/14-pin male interrupter
interface cable (Item 1) to the VFI Tester at the interrupter port. Refer to Figure 7 for steps 3 through 17.
4. Break the connection between the control and VFI
unit by disconnecting the VFI control cable (Item 2)
from the male receptacle located on the outside of
the TPG control enclosure.
Item 1
Interrupter
Interface
Cable
VFI
TO INTERRUPTER
EXTERNAL
TRIPPERS
INTERNAL
TRIPPERS
TO CONTROL
Tester
CONTROL
TEST
Afl
Bfl
Cfl
CURRENT
METER JACKS
TEST SELECT
PHASE SELECT
A-PHASE TRIPPER
5. Connect the 14-pin male connector end of the tester
interrupter interface cable (Item 1) to the 14-pin
female end of the padmount cable (Item 2) originating from the front plate of the VFI unit under test.
B-PHASE TRIPPER
BATTERY
CONNECTOR
14-pin female
connector at
cable end
ON
ON
ON
ON
30A
60A
120A
240A
C-PHASE TRIPPER
BATTERY TEST
ON
2X
4-30A
TRIPPER TEST
1X
4-30A
TEST
6. Place the Phase Test Selector switch on the VFI
tester into the EXTERNAL TRIPPERS position.
7. Place the Phase Selector switch into the A-PHASE
position.
8. Energize the tester by setting the power switch to ON.
9. Press the Tripper Test button. The A-Phase flux-shift
tripper in the padmount unit should operate immediately.
RESET
CONTROL
TEST
INPUT
POWER
120 VAC
Power Systems
CONVENIENCE
OUTLET
120 VAC
Figure 7.
Connection of the VFI Tester to side-hinged VFI
units with TPG controls for External Flux-shift
Tripper Test.
17
VFI Tester Operating Instructions
Top-Hinged VFI Units with TPG
Controls/All Tri-Phase Controls
1. Remove the padmount unit from service.
2. Attach the power cable to the VFI tester and plug it
into a grounded, three-prong 120 Vac outlet.
3. Connect the 14-pin female/18-pin male interrupter
interface cable (Item 1) to the VFI Tester at the interrupter port. Refer to Figure 8 for steps 3 through 17.
WARNING: Hazardous voltage. Open the
switch associated with the control before attempting to disconnect its control cable. Failure to do so can
result in contact with high voltage pulse (300 V peak)
from the CT protection circuit, which can cause death
or severe personal injury.
T287.0
!
CAUTION: Equipment damage. Use care while disconnecting and reconnecting cables to the TriPhase/TPG control. Do not misalign male and female
connectors or allow the full weight of the tester cable to
be transferred to the Tri-Phase/TPG board. Failure to
comply can result in damage to the board header and
possible equipment misoperation.
T319.0
16. Carefully reconnect the internal VFI control wiring
harness (Item 2) to the control board header.
17. Disconnect the 18-pin male connector end of the VFI
tester interrupter interface cable (Item 1) from the VFI
tester.
18. Using a hotstick, close in all three phases on the padmount unit.
4. Break the connection between the control and VFI
unit by carefully disconnecting the internal VFI control wiring harness (Item 2) at the control.
CAUTION: Equipment damage. Use care while disconnecting and reconnecting cables to the TriPhase/TPG control. Do not misalign male and female
connectors or allow the full weight of the tester cable to
be transferred to the Tri-Phase/TPG board. Failure to
comply can result in damage to the board header and
possible equipment misoperation.
T319.0
5. Connect the 18-pin male connector end of the VFI
tester interrupter interface cable (Item 1) to the
18-pin female end of the VFI control wire harness
(Item 2).
Tri-Phase/
TPG Board
Item 2
VFI
Control
Wire
Harness
18-pin female
connector
18-pin recessed
male connector
VFI
TO INTERRUPTER
B
A
L
C
M
D
P
N
E
F
EXTERNAL
TRIPPERS
INTERNAL
TRIPPERS
TO CONTROL
Tester
M
L
U
T
CONTROL
TEST
Afl
Bfl
A
N
V
S
P
R
Cfl
CURRENT
METER JACKS
TEST SELECT
PHASE SELECT
A-PHASE TRIPPER
6. Place the Phase Test Selector switch on the VFI
tester into the EXTERNAL TRIPPERS position.
7. Place the Phase Selector switch into the A-PHASE
position.
Item 1
Interrupter
Interface
Cable
ON
ON
ON
ON
30A
60A
120A
240A
C-PHASE TRIPPER
BATTERY TEST
ON
2X
4-30A
TRIPPER TEST
1X
4-30A
TEST
RESET
CONTROL
TEST
INPUT
POWER
120 VAC
8. Energize the tester by setting the power switch to ON.
9. Press the Tripper Test button. The A-Phase flux-shift
tripper in the padmount unit should operate immediately.
B-PHASE TRIPPER
BATTERY
CONNECTOR
Power Systems
CONVENIENCE
OUTLET
120 VAC
Figure 8.
Connection of the VFI Tester to top-hinged VFI units
with TPG controls and all VFI units for external
Flux-shift Tripper Test.
10. Place the Phase Selector switch into the B-PHASE
position.
11. Press the Tripper Test button. The B-Phase flux-shift
tripper in the padmount unit should operate immediately.
12. Place the Phase Selector switch into the C-PHASE
position.
13. Press the Tripper Test button. The C-Phase flux-shift
tripper in the padmount unit should operate immediately.
14. De-energize the tester by setting the power switch to
OFF.
15. Disconnect the 18-pin male connector end of the VFI
tester interrupter interface cable (Item 1) from the
18-pin female end of the VFI control wire harness
(Item 2).
18
Battery Test
Refer to Figure 3 for identification of individual VFI Tester
switches and other features referenced within the following procedure.
The VFI tester features an LCD screen, battery connection terminal,0 and push button for verifying the battery
condition under load. The procedure for conducting a
battery test is as follows:
1. Disconnect and remove the 15 Vdc lithium battery
from the control.
2. Connect the 15 Vdc lithium battery to the battery test
terminals located on the front panel of the VFI tester.
3. Press and release the Battery Test button.
!
SAFETY
FOR LIFE
S285-10-7
4. If the battery passes the test, the LCD display of the
tester will display the ‘Battery Good’ message.
Batteries passing the battery test may be placed
back into service.
5. If the battery fails the test, the LCD display of the
tester will display the ‘Replace Battery’ message.
Replace the exhausted battery with a new, equivalent battery. Exhausted batteries should be disposed
of in an environmentally responsible manner. Consult
local regulations regarding proper battery disposal.
Note: Control tests can not be conducted during a battery test.
SERVICE INFORMATION
VFI Tester units have no user serviceable components.
Do not attempt to perform any service or maintenance on
these units.
Factory Authorized Service
Centers
Factory authorized service centers are located throughout the continental United States to provide maintenance, repair, and testing services for Kyle Products. For
further information, contact your Cooper Power Systems
sales representative.
19
VFI Tester Operating Instructions
APPENDIX A
TABLE 2
LCD Message Screens
Screen No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
20
Screen Text
VFI Tester Revision XX.xx
Test Aborted Thermal Shutdown
Description
Initial Screen on Power-up. Shows the current firmware version.
Displayed when VFI tester is shut off during an over-temperature
condition.
Tester Ready to Resume Testing
Displayed after VFI tester has cooled down from an overtemperature condition.
Initializing Battery Test
Displayed when VFI tester verifies battery condition
Verify Battery Connection
Displayed if battery voltage measured during initialization is below 0.5V
Test in Progress Time Remaining X Sec Displayed while battery load test is in progress.
Test Complete Replace Battery
Displayed after battery load test, if battery failed test.
Test Complete Battery Good
Displayed after battery load test, if battery passed test
Control Test: XXX.xxx Seconds
Displayed during a control test. Shows the elapsed time of the test.
Test Stopped Seconds: XXX.xxx
Displayed if user manually stops the control test
Control Test Timed Out
Displayed if the control test exceeded 5 minutes
A-Phase Trip: XXX.xxx Seconds
Indicates elapsed time between initialization of the A-Phase control test
and execution of a trip command by the VFI control board.
B-Phase Trip: XXX.xxx Seconds
Indicates elapsed time between initialization of the B-Phase control test
and execution of a trip command by the VFI control board.
C-Phase Trip: XXX.xxx Seconds
Indicates elapsed time between initialization of the C-Phase control test
and execution of a trip command by the VFI control board.
A-, B-Phase Trip: XXX.xxx Seconds
Indicates only A- and B-Phase tripped during 3-phase trip test.
Conduct single-phase trip test of C-phase to verify control and flux-shift
tripper operation.
A-, C-Phase Trip: XXX.xxx Seconds
Indicates only A- and C-Phase tripped during 3-phase trip test
Conduct single-phase trip test of B-phase to verify control and flux-shift
tripper operation.
B-, C-Phase Trip: XXX.xxx Seconds
Indicates only B- and C-Phase tripped during 3-phase trip test
Conduct single-phase trip test of A-phase to verify control and flux-shift
tripper operation.
A, B, C Phase Trip: XXX.xxx Seconds
Indicates elapsed time between initialization of ganged, A-, B-, and
C-phase control test and execution of a trip command by the VFI
control board.
!
S285-10-7
SAFETY
FOR LIFE
APPENDIX B
Phase Minimum Trip
Dip Switches
Instantaneous Trip
Dip Switches
Independent
or 3-phase
Trip Selector
Switch
Figure 9.
Kyle® Tri-Phase Board.
040001KM
21
VFI Tester Operating Instructions
Phase
Minimum Trip
Ground Minimum
Trip Dip Switch
Phase Instantaneous
Trip Dip Switch
Ground Trip
Block Switch
Ground Instantaneous
Trip Dip Switch
Independent
or 3-phase
Trip Selector
Switch
Figure 10.
Kyle® TPG Board.
22
040002KM
!
S285-10-7
SAFETY
FOR LIFE
Minimum Trip Multiplier Switch
Inrush Restraint
Reset Time
Dip Switch
SCADA
Fault Targets
Minimum Trip Multiplier
Dip Switches
Inrush
Restraint
Dip Switch
Ground Trip Block
During Inrush Switch
Figure 11.
Optional SCADA Board Accessory-TPG only
23
040003KM
23
VFI Tester Operating Instructions
!
SAFETY
FOR LIFE
©2005 Cooper Power Systems or its affiliates.
Kyle® is a registered trademark of Cooper Power Systems or its affiliates.
KA2048-627 Rev: 00
1045 Hickory Street
Pewaukee, WI 53072
www.cooperpower.com
KDL
1/05